Soft diaper tape

ABSTRACT

A fastener tab for disposable diapers has improved tactile softness provided by surface morphologies of preselected projection and/or relief dimensions.

This is a continuation of application Ser. No. 08/057,043, filed May 3,1993, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to tabs for disposable diapers, geriatric briefs,surgical drapes or other articles requiring a fastener tab and to tapesconvertible to make such tabs.

In the manufacture of disposable diapers, it is typical practice for thediaper manufacturer to provide diaper fastener tabs fixed to the diaperproper. Each tab is permanently attached at one end thereof to thediaper shell at a "factory joint" at the rear of the diaper. The otherend of the tab is arranged for fastening and refastening the diaperclosed to a reinforcing tape or landing zone at a "user joint" at thefront of the diaper. To that end, the tab includes a polymeric substrateor backing film and an adhesive layer.

It is desirable to provide such tabs with an increased softness. Suchsoftness may be provided for aesthetic and/or functional purposes asdiscussed more fully below.

Tactile softness may be desirable solely for aesthetic purposes as wellas for infant comfort. Pliant softness characterized by highly flexibleor conformable film deformation properties provides infant comfort byreducing the tendency to chafe or irritate the infant's skin uponcontact. To some extent, both tactile and pliant film softness maycombine to reduce chafing and irritation.

Heretofore, tactile and/or pliant film softness have been provided byformulation of the polymeric film with polymers of relatively lowermodulus. For example, polyethylene homopolymers may be used to provide arelatively soft feeling and highly flexible tab substrate or backingfilm. Similarly, polyethylene may be combined as a copolymer orphysically blended with other polymers such as polypropylene to increasethe softness of the resulting copolymer or polymer blend. Otherpolymers, such as ethylene-vinyl acetate (EVA) may also be used ascopolymer or blended constituents.

The use of polyethylene homopolymers, copolymers or blends to achievetab softness is not entirely satisfactory since polyethylene tends tocause adhesive aging problems characterized by accelerated rates ofdecrease of adhesion strength with age. The aging problems are believedto be associated with the tendency of one or more adhesive components tomigrate into the polyethylene moiety (polyethylene copolymer or blendedmaterial) with swelling of the latter. In the case of polypropyleneblends and copolymers with polyethylene, it is believed that no morethan about five percent polyethylene by weight may be present in orderto avoid unacceptable adhesive aging characteristics.

As compared with films of polypropylene homopolymer, polyethylenecopolymers and physical blends tend to be characterized by lower modulusvalues. Therefore, it is expected that tab substrate or backing films ofsuch polyethylene materials will require slightly higher thicknessesthan the 4.2 to 6 mil thicknesses used for polypropylene in order toassure film stability and ease of handling during machine processing. Ofcourse, such polyethylene, polypropylene and/or copolymers thereof athigher thicknesses also tend to result in a cost disadvantage due to theadditional material costs and the higher costs of copolymer films ascompared with homopolymer films.

The outer side of polymeric fastener tabs have been embossed to providethem with a roughened outer surface. Various embossing patterns haveresulted in corresponding degrees of roughness. One convenient measureof surface roughness is provided by the "Ra" roughness average or valuemeasured in angstroms with a Dektak 3030 profile measuring system usinga 2.5 um radius stylus. (The Dektak 3030 profile measuring system ismanufactured by the Sloan Technology subsidiary of Veeco InstrumentsInc. of Santa Barbara, Calif.) The Ra roughness average or value of asurface is defined as the distance between the average peak orprojection height and an imaginary median line on the sample surfacepositioned so that the areas enclosed by the peak portions above theline will be equal to the areas enclosed by the valleys between the peakportions below the line. Hereinafter, such Ra roughness averages orvalues are reported to indicate the relative roughnesses of surfacemorphologies.

Prior art diaper fastener tabs have been found to range in roughnessfrom Ra values of 25,000 angstroms to 170,000 angstroms due to variousfinish processing techniques including embossing. Presumably suchroughness is used to avoid the gloss finish otherwise obtained by finishrolling plastic film with a polished steel roll.

It is known from U.S. Pat. No. 5,147,347 to emboss or otherwise texturethe outer surface of a diaper shell to provide a non-glossy, mattefinish material which the patentee indicates is soft to the touch,provides a more garment-like appearance, and produces less rattlingnoise when manipulated. It is believed that such diaper shell rougheningtends to cause poor adhesive contact efficiency which is associated withthe inadvertent "pop-off" release of diaper tabs and/or tears of thediaper shell at the factory joint. The contact efficiency is reduced bysurface morphologies of relatively rough characteristics havingsignificant variations in surface projections and/or relief dimensions.In some instances, the contact efficiency is further decreased byroughening of the fastener tab adhesive layer during processing. Moreparticularly, fastener tabs are typically formed of self-wound tapes andthe adhesive layer of the wound tape replicates the roughness orembossing pattern of the substrate. The exposed surface of the adhesivelayer of the tab is thereby roughened and itself may further inhibitadhesive contact efficiency.

SUMMARY OF THE INVENTION

It has now been discovered that film surfaces of increased tactilesoftness may be provided by selected film surface morphologies. Suchfilm surface morphologies are characterized by patterns of preselectedprojection and/or relief dimensions.

The surface morphology may be selected to sufficiently increase thetactile softness of the film to impart acceptable hand sensed softnessto a film which would otherwise be perceived as too stiff upon handmanipulation. Thus, the tactile softness achieved by the surfacemorphology in accordance with the invention enables a degree of maskingor concealing of modulus and/or thickness derived film stiffness. Inthis manner, the surface morphology enables the use of relatively highermodulus and thickness polymeric film materials. However, higher modulusmaterials are preferably used at relatively lower thicknesses in orderto reduce costs and further increase film softness as compared withprior art fastener tab polymeric film substrates or backing films.Herein, backing films having a thickness between 1 to 4 mils areprovided. Applicant is not aware of a prior art diaper tab backing filmhaving a thickness of about 4 mils or less.

Another important advantage of the present invention is the ability toavoid the use of polyethylene or other troublesome constituents in thepolymeric film material in order to achieve softness. This enables theprior art adhesive aging problems associated with the use ofpolyethylene to be avoided. Accordingly, the surface morphology enableschanges in film compositions, as well as film modulus and thicknessproperties as discussed above, which cooperate in a synergistic mannerto provide films of improved softness, strength and durability.

It is not necessary that film compositions in accordance with theinvention be free of all polyethylene. In certain machine processingapplications, the film composition may include a small amount ofpolyethylene (e.g. 0.5 to 3%) to avoid film shattering. Thus, thepresence of polyethylene does not inhibit the practice of the inventionand, in fact, the softness improvements of the invention may be appliedto polyethylene materials.

It has also been found that the film surface morphology may reduce theoccurrence of tab "pop-off" disengagement and/or diaper shell tearing.More particularly, the surface morphology may be selected to besufficiently less rough than that of the prior art tabs or tapes so asto achieve improved adhesive contact efficiency.

The improvements of the invention are obtained with film surfacemorphologies having Ra values in the range of from about 7,000 angstromsor lower up to about 14,700 angstroms. More preferably, the Ra valueswill be in the range of from about 8,000 to 10,000 angstroms.

The exact lower limit of the Ra value corresponding with the tactilesoftness improvements of the invention has not been determined. As apractical matter, lesser improvements in tactile softness may beexpected with increasing smoothness approaching that of a gloss finishobtained by forming the film surface with a polished steel roll as suchsoftness improvements become no longer subjectively perceivable by handmanipulation of the film. The gloss finish surface of a film is notdeemed to provide desirable tactile properties.

A preferred method of providing film surface roughness is embossing.This may be done immediately following film formation or it may comprisea subsequent processing step.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, all of which are highly diagrammatic and do not showvarious elements to scale,

FIG. 1 is a plan view of a disposable diaper having fastener tabs inaccordance with the invention;

FIG. 2 is a cross-sectional view on an enlarged scale of one of thefastener tabs of FIG. 1 prior to its application to the diaper;

FIG. 3 is a cross-sectional view similar to FIG. 2 showing anotherembodiment of a fastener tab in accordance with the invention;

FIG. 4 is a schematic view showing process steps for making a substrateor backing film for use in making the fastener tab of FIG. 1;

FIG. 5 is a schematic view showing process steps for making andconverting a tape to form the fastener tab of FIG. 1;

FIG. 6 is a cross-sectional view on an enlarged scale showing theattachment of one of the fastener tabs at a factory joint to the diaperof FIG. 1;

FIG. 7 is a cross-sectional view similar to FIG. 6 showing theattachment of the fastener tab at a factory joint using a "Y-bond";

FIG. 8 is a photomicrograph at 100X magnification of the surface of theouter side or embossed side of a polymeric substrate film for a fastenertab in accordance with the invention; and

FIG. 9 is a photomicrograph at 100X magnification of an outer surface ofa prior art polymeric substrate film for a fastener tab.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to FIG. 1, a disposable diaper 10 includes a plastic filmouter layer or shell 12 and an absorbent layer or body 14 disposedbetween the shell 12 and a top sheet 16. The top sheet 16 tends toseparate an infant from moisture absorbed in the body 14. As shown, theshell 12 and top sheet 16 are coterminous and extend past both thelateral and longitudinal edges of the body 14.

The shell 12 has a front waistband section 18 and a rear waistbandsection 20 connected by a narrowed intermediate crotch section 22. Areinforcing tape 24 is permanently attached along the front waistbandsection 18 of the diaper shell 12. The tape 24 provides a landingsurface or zone 26 for adhesive connection with a pair of identicalfastener or fastening tabs 30 mounted to associated lateral ends of therear waistband section 20. Each of the tabs 30 has an elongate shape andis sized to extend from a factory joint 32 securing the tab to thediaper shell 12 at the rear waistband section 20 to a user joint 34(shown in dotted outline) at the landing surface 24 for fastening andrefastening the diaper closed about an infant.

Referring to FIG. 2, the tab 30 includes a release layer or coating 36,a polymeric substrate or backing film 38 and an adhesive layer 40. Asdescribed more fully below, the release layer 36, film 38 and adhesivelayer 40 are of known compositions. However, certain prior artrestraints in the selection of the polymeric components of the adhesivelayer 40 are removed in accordance with the invention.

The film 38 may be prepared by extrusion or casting techniques withcharge formulation or subsequent processing to provide the desiredsurface morphology as described below. The film 38 includes an outer orexposed side 42 and an inner or adhesive side 44. The exposed side 42 isprovided with a selected surface morphology to achieve improved tactilesoftness. The adhesive side 44 generally has a smoother surface than theexposed side 42.

The surface morphology of the exposed side 42 is characterized by arandom roughness or texture within a selected range of roughness. Thesurface morphology may be provided by any suitable texturing techniqueincluding embossing or abrading the film as well as the addition ofmatting agents to the resin composition of the film. A presentlypreferred technique comprises embossing the film immediately uponmanufacture with an engraved embossing roll having a random pattern.Useful steel embossing rolls having a random roughness pattern providedby a sand blasting technique and a chrome finish coat are disclosed inU.S. Pat. No. 4,436,520. A suitable roll roughness is characterized ashaving a projection and/or relief profile wherein the root mean squareof the projection heights is 45 microinches and the roll is referred toas a "45 RMS roll. A 45 RMS roll results in a film having a Ra valueranging from 9,000 to 13,000 angstroms when used to immediately embossand chill the extruded film. Increasing RMS roll numbers result inincreasing roughness, e.g. 99 RMS corresponds with a Ra value of about25,000 angstroms and 250 RMS corresponds with a Ra value of from 68,830to 75,830 angstroms.

The film 38 may be formed of a suitable film forming resin such as apolyolefin homopolymer, copolymer or blend, and it may include otherpolymeric constituents or additives. Preferred materials includepolypropylene homopolymer and copolymers and blends with lesser amountsof other constituents. The polypropylene polymers are preferred sincethey provide relatively higher moduli in the range of 80,000 to 250,000psi as measured using ASTM D882-88.

As indicated, the tactile softness improvements of the surfacemorphologies tend to mask or conceal the hand perceptible stiffness ofhigher modulus polymers so as to enable the use of thinner films ofhigher modulus materials. Accordingly, films having modulus values inthe range of 80,000 to 250,000 psi and gages less than about 4 mils havebeen used as backing film for fastener tabs. The advantages of highmodulus films of relatively thinner gage include higher strength, goodmachine processing characteristics with an acceptable amount of stretch,reduced caliper and less cost, lesser tendency to shatter, andsignificantly lower film rigidity since the rigidity is proportional tothe cube of the film thickness.

As noted above, the adhesive layer 40 may be a known adhesive materialsuch as pressure-sensitive adhesives including acrylic resin and naturalor synthetic based rubber adhesives. Preferred adhesives include hotmelt pressure-sensitive adhesives of the A-B-A block copolymer typecomprising an elastomeric B-block derived from isoprene andthermoplastic A-blocks derived from styrene as disclosed in U.S. Pat.No. 3,932,328. Illustrative rubber based adhesives includestyrene-isoprene-styrene and styrene-butadiene-styrene which mayoptionally contain diblock components such as styrene isoprene andstyrene butadiene. It is also possible to use adhesives of differentcompositions at opposed terminal ends of the tabs to provide factory anduser joints of different adhesives. The adhesives may be applied usinghot-melt, solvent or emulsion techniques. The adhesive layer 40 may bedirectly coated onto the film 38 or transfer coated using knowntechniques. The adhesive layer may range from about 0.5 to 2.5 mils inthickness.

The release layer 36 may be of known compositions such as silicones,vinyl carbamates and acrylics. The release layer may be applied usingconventional application techniques such as roll or gravure coating.Typical coating weights range from 0.2 to 2 grams/meter². The releaselayer does not interfere with the softness improvements obtained by thesurface morphologies of the invention.

Referring to FIG. 3, a modified fastener tab 50 is shown. The tab 50includes release layer 36 and adhesive layer 40 which are identical withthose described above in connection with the fastener tab 30. However,the tab 50 includes a multilayer substrate or backing film 52 having atop layer 54 and bottom layer 56 integrally and uniformly joined alongan interior interface 58. The top layer 54 provides an outer or exposedside 60 and the bottom layer 56 provides an inner or adhesive side 62.The top and bottom layers 54 and 56 may be formed of different polymericmaterials and/or additives in order to provide different film propertiesor characteristics at the exposed and adhesive sides of the film 52. Forexample, the top layer 54 may be formed of an appearance selectedpolymer and the bottom layer 56 may be a strength selected polymer. Thefilm 52 may be formed by lamination or coextrusion of the two layers 54and 56. Also, the film 52 may be formed of three layers in an A-B-Aarrangement, or more than three layers may be used.

Referring to FIG. 4, a process is shown for the manufacture of a film 70which may be converted to provide substrate or backing film 38 for usein the tab 30. The film 70 is prepared by extrusion of a suitable resincharge, such as polypropylene homopolymer from an extruder 72 into thenip formed by a rubber back-up roll 74 and an engraved embossing orchill roll 76. The extruded resin may be at a temperature of about 300°F. as it exits the extruder 70 and it is chilled upon contact with theroll 76 which is at a temperature of 60° to 100° F. As the resin passesthrough the nip and around the roll 76, the film 70 is formed andembossed. Thus, a first side of the film 70 is embossed to provide thedesired surface morphology for use as the fastener tab outer side 42 andthe second side of the film 70 has a smoother surface for use as thefastener tab adhesive side 44.

The film 70 passes from the roll 76 into a nip formed by a rubberback-up roll 78 and a chill roll 80 to further reduce the temperature ofthe film. The film is then trained through a pair of corona treatmentunits 82 to improve the anchorage of the release coat, adhesive layerand any printing which may be applied to the surfaces of the film. Thecorona treated film 70 is then wound in a roll 84 for storage andfurther processing.

The continued processing of the film 70 is illustrated in FIG. 5 wherethe roll 84 is unwound and the film 70 is passed to a release coatingstation "R" for application of release coat 36 to the embossed side ofthe film. Thereafter, the adhesive layer 40 is applied to the oppositeside of the film 70 at an adhesive coating station "A". The film is thenslit at a slitting station "S" in a lengthwise or machine direction toform a plurality of fastener tapes 86. Each of the tapes 86 has a widthcorresponding with the desired fastener tab length. The tapes areself-wound into fastener tape rolls 88 for further processing ortransport. Typically, the fastener tape rolls 88 are converted tofastener tabs 30 by cutting across the width of the tapes 86 during thefinal steps of diaper manufacture and applied to the diapers usingautomatic machine processing.

It will be understood that the operations shown in FIGS. 4 and 5 willoften be done at different locations by different manufacturers, or theymay be combined. For example, the steps shown in FIG. 4 may be done by afilm supplier and the steps shown in FIG. 5 may be done by a tapemanufacturer.

Referring to FIG. 6, the fastener tab 30 is shown applied to the diaper10. The fastener tab 30 is cut to a length of about 2.5 to 3" dependingupon the diaper size. A first terminal segment 30a of the tab 30 isadhered at factory joint 32 to the associated lateral edge of the rearwaistband section 20 of the diaper 10. An opposite terminal segment 30bof the tab 30 is folded over on itself to form a finger lift 90 for usein deploying the tab from its stored position. For purposes of storingthe tab 30, a release tape 92 is adhered to the top sheet 16 of thediaper opposite the factory joint 32. The release tape 92 has a releasecoating on its outer surface. The over-hanging or extending portion ofthe tab 30 is folded around the lateral edge of the diaper 10 andremovably secured to the release coating on the tape 92 for temporarystorage of the tab prior to its deployment to a diaper fasteningposition at user joint 30 on the landing zone 26 of the reinforcing tape24.

Referring to FIG. 7, the fastener tab 30 is shown applied to the diaper10 using a "Y-bond" mounting arrangement. In this instance, the releasetape 92' has a longer length. More particularly, the release tape 92'extends beyond the lateral extremity of the diaper 10 and intoengagement with an adjacent portion of the adhesive layer 40.

In the following Table I, Examples 1-10 of specific fastener tabsubstrate films further illustrate the invention and comparative Example1C and 2C illustrate known prior art substrate films. The films wereprepared using the processes of FIGS. 4 and 5 unless otherwise noted.The physical properties reported in Table I were measured at least sevendays after film manufacture. The strength of these films ascharacterized by the reported modulus and yield point values indicatesmachine processability at customary conditions.

The films of Examples 1-9 and Comparative Examples 1C and 2C were formedby extruding charges of polypropylene homopolymer (PP), polyethylenehomopolymer (PE), and blends or copolymers thereof as indicated below.The extruded films were immediately embossed using either a 45 RMS or250 RMS random pattern embossing roll formed by sand blasting a steelroll and applying a chrome finish coat finish to the roll embossingsurface.

The film of Example 10 was formed using a biaxially orientedpolypropylene film sold under the designation TORAYFAN by Toray PlasticsAmerica, Inc. of North Kingston, R.I. This film is believed to comprisea laminate of three polypropylene layers, and it is available inthicknesses ranging from about 1 to about 3 mils. A suitable surfaceroughness results from the manufacturing process without a separateembossing step.

Each of the films of the examples and comparative examples was combinedwith an adhesive layer of hot melt pressure-sensitive adhesive of theA-B-A block copolymer type as disclosed in U.S. Pat. No. 3,932,328. Onespecific adhesive formulation is set forth below.

    ______________________________________                                        Component       Weight Percent                                                ______________________________________                                        Kraton 1107     31.7                                                          Escorez 1310 LC2                                                                              46.3                                                          Wingtack 10     19.8                                                          Ethanox 330     1.0                                                           Plastonox LDTP  0.9                                                           ______________________________________                                    

KRATON 1107 is a polystyrene-isoprene-polystyrene linear block copolymersold by Shell Chemical Co. ESCOREZ 1310 LC is a solid C₅ tackifyingresin sold by Exxon Chemical Corp. WINGTACK 10 is a solid C₅ tackifyingresin sold by Goodyear Chemical Co. ETHANOX 330 is a phenolicantioxidant sold by Ethyl Corporation. PLASTONOX LDTP is a thioesterantioxidant sold by American Cyanamid Company.

The films of Examples 1-10 have satisfactory tactile and pliant softnesscharacteristics based on finger touching the film surface and handmanipulation of the film. The films of Comparative Examples 1C and 2C donot have satisfactory pliant softness as measured by hand manipulationof the film. The films of Comparative Examples 1C and 2C were alsodetermined to be of a lesser tactile softness than the films of Examples1-10 as determined by finger touching of the film surfaces and indicatedby the Ra values.

                  TABLE I                                                         ______________________________________                                        Ex-                                                                           ample                                                                         Num-  Film     Gage.sup.1                                                                            Yield.sup.2                                                                         Modulus.sup.3                                                                          Ra                                      ber   Polymer  (mils)  (#/in.)                                                                             (psi)    (Å)                                 ______________________________________                                        1     PP       3.30    8.88  88930 ± 1680                                                                        9000-13000.sup.8                        2     PP       4.74    14.01 88990 ± 7990                                                                        "                                       3     PP       6.47    18.92 74410 ± 5930                                                                        "                                       4     PP/PE.sup.4                                                                            3.36    7.10  65840 ± 3700                                                                        "                                       5     PP/PE.sup.4                                                                            5.01    11.10 61890 ± 2460                                                                        "                                       6     PP/PE.sup.4                                                                            6.58    14.78 56440 ± 3340                                                                        "                                       7     PE       3.38    4.27  19040 ± 330                                                                         "                                       8     PE       5.00    6.23  19690 ± 360                                                                         "                                       9     PE       6.62    8.45  19620 ± 60                                                                          "                                       10    .sup. PP.sup.5                                                                         1.00    --    250000.sup.7                                                                           8720-10720.sup.                         .sup. 1C                                                                            PP       4.27    12.77 99560 ± 1865                                                                        68830-75830.sup.9                       .sup. 2C                                                                            PP/PE.sup.6                                                                            4.60    11.36 79440 ± 2490                                                                        "                                       ______________________________________                                         .sup.1 Yield average gage -- ASTM E25284.                                     .sup.2 Crossdirection yield point -- ASTM D432183.                            .sup.3 Crossdirection modulus -- ASTM D88288.                                 .sup.4 50/50 blend.                                                           .sup.5 Three layer laminate.                                                  .sup.6 Random copolymer of PP and 2.5% PE.                                    .sup.7 Film manufacturer data.                                                .sup.8 Estimate based on use of 45 RMS roll.                                  .sup.9 Estimate based on use of 250 RMS roll.                            

It is presently believed that the films of the invention may have across-direction (CD) modulus as low as 19,500 psi and a cross-directionyield point of about 4 lbs./inch or higher. More preferably, thecross-direction modulus is about 24,000 psi and the cross-directionyield point is about 6 lbs./inch or higher. The most preferred filmshave a cross-direction modulus of about 80,000 psi or higher and across-direction yield point of about 9.0 lbs./inch or higher.

Referring to FIG. 8, the surface of an outer side of a substrate film ofa fastener tab in accordance with the invention is shown at 100Xmagnification. As indicated above, this film was formed of an extrudedpolypropylene homopolymer which was embossed with a 45 RMS chrome coatedsteel embossing roll. The Ra value ranges from 7,070 to 14,610angstroms, and the surface is characterized by a large number of closelyspaced discrete projections or asperities of generally uniform height.

Referring to FIG. 9, the surface of an outer side of a prior artfastener tab in accordance with Example 2C is shown at 100Xmagnification. This film was extruded and embossed with a 250 RMS rollso as to result in a Ra value of about 72,330±3,500 angstroms. This filmsurface is characterized by intersecting or overlapping projectionsyielding an orange peel appearance. The projections are substantiallylarger than those obtained in accordance with the invention.

While the invention has been shown and described with respect toparticular embodiments thereof, this is for the purpose of illustrationrather than limitation, and other variations and modifications of thespecific embodiments herein shown and described will be apparent tothose skilled in the art all within the intended spirit and scope of theinvention. For example, although illustrated in respect to reinforceddiapers, the invention also contemplates non-reinforced diaperapplications wherein the tab is fastened closed by direct adhesiveclosure to the diaper shell. Accordingly, the patent is not limited inscope and effect to the specific embodiments herein shown and describednor in any other way that is inconsistent with the extent to which theprogress in the art has been advanced by the invention.

What is claimed is:
 1. A fastener tab suitable for disposable diapers orother tab fastened articles comprising a backing film of polymeric resinand an adhesive layer for fastening and refastening, said film having anexposed outer side and said adhesive layer having an exposed adhesiveside, said tab having a length extending between terminal segmentsthereof for forming a factory joint to secure said fastener tab to saidtab fastened article at one terminal segment and a user joint to fastenand refasten said tab fastened article closed at the other terminalsegment, and said outer side including a surface morphology having aroughness average value of from about 7,000 to about 14,700 angstroms,said surface morphology providing increased tactile softness as comparedwith a similar film having a rougher surface morphology.
 2. The fastenertab of claim 1, wherein said film has a cross-direction modulus greaterthan 19,500 psi and a thickness in the range of from about 1 mil toabout 4 mils.
 3. The fastener tab of claim 2, wherein said adhesivelayer is a pressure-sensitive adhesive.
 4. The fastener tab of claim 2,wherein said adhesive layer is a natural or rubber basedpressure-sensitive adhesive.
 5. The fastener tab of claim 4, whereinsaid polymeric resin contains less than 5% polyethylene to render itsubstantially resistant to migration of components of said adhesive intosaid film to thereby substantially prevent or reduce aging of saidadhesive layer.
 6. The fastener tab of claim 2, wherein said outer sideis embossed to provide said surface Morphology.
 7. The fastener tab ofclaim 6, wherein said surface morphology enables the use of films ofhigher modulus and decreased thickness without corresponding decreasesin tactile softness and tensile strength.
 8. The fastener tab of claim6, wherein said film has a cross-direction modulus in the range of fromabout 80,000 to about 250,000 psi. and a cross-direction yield point of9 lbs./inch or higher.
 9. The fastener tab of claim 8, wherein said filmincludes polypropylene as its major component.
 10. The fastener tab ofclaim 9, wherein said roughness average value is in the range of fromabout 8,000 to about 10,000 angstroms.
 11. The fastener tab of claim 1in combination with a disposable diaper including a plastic shell havingan exterior surface that has been toughened, said fastener tab beingadhered to said exterior shell surface at a factory joint, said exposedadhesive side of said adhesive layer having a surface morphology that isa replication of said exposed outer side of said film and therebyproviding improved contact efficiency between said adhesive layer andexterior shell surface to reduce the tendency of said tab to pop-off ordisengage from said factory joint.